JPS6011352A - Cushion member - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention] The present invention relates to a cushion member.

Specifically, it is used as an interlayer in cushioning materials with good breathability and durability used for automobile seats and the like.

Conventionally, seats used in vehicles such as automobiles are made by placing a cushioning material such as a plain weave fabric of tape such as polyethylene or polypropylene or palm rock material, and a polyurethane foam on the cushioning material, and then using the polyurethane foam. A seat body whose surface is covered with a skin material and mounted on a spring adjusted to a frame is mainly used.

However, these seats have poor ventilation because none of the materials that make up their groove bottoms have breathability, and they cannot dissipate the body heat of the occupants or the heat from the outside air. This was causing discomfort to passengers. Further, since the cushioning material of the seat body is mainly made of polyurethane foam, if it is placed directly on the spring, the polyurethane foam will be cut at the contact surface with the spring after long-term use. For this reason, direct contact between the polyurethane foam and the spring is avoided, and cushioning materials such as palm rock material, polyethylene nonwoven fabric, and polyethylene and polypropylene heshan cloth (plain weave) are used. However, the use of such a cushioning material not only increases cost but also reduces the cushioning properties and does not provide an air dispersion effect from the lower part.

In addition, since polyurethane has lower pressure elasticity than the M fiber cushioning material, the polyurethane foam layer needs to be thicker in order to maintain good cushioning properties, and this overlaps with the thickness of the spring receiving material, making the entire seat higher. This had the disadvantage of making the entire car body taller.

On the other hand, as a cushioning material with relatively good air permeability, a cushioning member is known in which a locking material made of short synthetic fibers is integrally bonded as a sheet-like surface decoy to at least a portion of the surface of a base made of palmlock material. Yes (Unexamined Japanese Patent Publication No. 52-1
01.164).

However, since the base material of this type of cushioning material is primarily palm rock, it is heavy, and because it is hygroscopic, it not only poses problems in reducing the weight of automobiles, but also has problems in durability. . Particularly when used for a long period of time, there is a drawback that the so-called "sagging" phenomenon is necessary and the cushioning properties and hardness decrease. Moreover,
There was a drawback that the desired air permeability could not be obtained.

The present invention has been made to solve the problems of the conventional products as described above, and is made by applying an adhesive to a filament molded body obtained by compression molding short polyester filament #i having three-dimensional curls into a predetermined shape. A filament obtained by compression molding short polynisdel filament fibers having three-dimensional curls into a predetermined shape on a lower filament cushioning material layer having a relatively high bulk density formed by bonding the contact points between the filaments. An upper filament cushioning material layer is provided, which is formed by applying an adhesive to the molded body to bond the contact points between the filaments and having a lower bulk density than the lower filament to the cushioning material layer, and the lower filament At least one filament in the cushioning material layer extending substantially from the lower surface thereof to the upper filament cushioning material layer.
This is a cushion member characterized by forming several holes.

The polyester filament used in the present invention has a thickness of 50 to 1 as a monofilament,
000 denier, preferably 100-600 denier,
Most preferably, the filament is 200 to 400 deniers and has three-dimensional curls. Here, three-dimensional curls are defined as
Bidirectional and tridirectional curl refers to three-dimensional curl in a broad sense, but preferably three-directional three-dimensional curl filament.
No. 48 by the method and treatment disclosed in
A double-twisted filament D as shown in the figure is made, then cut to a predetermined size and untwisted to obtain a three-dimensional three-dimensional curl filament as shown in Figure 2. The length is preferably between 25 and 200III. Thus, the filament section coils in section a over section b, and section C coils over section d. However, section e coils over section f. Rather than coiling over the helix, it coils under the king. Thus, the lection of the filament from e to d lies in the two entanglements or coils of the helix. This can properly be called a non-directional leash. It is very similar to a spiral telephone cord that goes bad when one of its coils becomes directionless relative to the other.

The lower filament cushion material layer has a bulk density of 0.
05~0.507cm3', preferably 0°1~0.
3g 7cm3. For such a cushioning material layer, (a) an adhesive is applied to an aggregate of polyester filament short fibers having three-dimensional curls, compressed to a predetermined bulk density, and an adhesive is applied if necessary. (b) a cushioning material having a structure in which each contact point between the filaments obtained by applying the method is bonded with an adhesive; (b) an aggregate of polyester filament staple fibers having three-dimensional curl;
The curled filaments have partially directional properties and are formed by stretching and deforming.The partially intertwined portions of curled filaments of various shapes are shaped in a direction in which load strength is to be produced. After forming and distributing the intertwined parts according to the required load strength and applying an adhesive, the filaments are compressed to a predetermined bulk density, and if necessary, an adhesive is applied. Each contact point of the cushion material is bonded with an adhesive.

Since the lower filament cushioning material layer is a compressed body of filament aggregates, it has some degree of breathability by itself, but it is insufficient, so at least one layer that almost reaches the two-layer filament cushioning material layer from its lower surface,
Preferably, a plurality of holes are formed so that 1'Cd5<. The diameter of this hole varies depending on the number of holes to be formed and the density of both the upper and lower filament cushioning material layers, but it is usually 1 to 40 nm+m, preferably 3 to 30 mm, and most preferably 3.5 to 201+1111 mm. Further, the ratio of the total area of the holes to the total area of the lower filament (-cushion material layer) is 0.1 to 30%, preferably 1 to 30%.
10%, most preferably 2-5%.

The upper filament cushion material layer has a bulk density of 0.
01~0.2(]/cm3, preferably 0°03~
0, IQ, /crn3. Such a cushioning material layer may be formed by forming an aggregate of polyester filaments that have the three-dimensional curl by stretching and deforming the filaments so that the curl shape partially has directionality. The partially entangled portions of the curled filaments having the shape of are formed by needling in the direction in which the load strength is desired, and the entangled portions are distributed according to the required strength, and an adhesive is used. There is a cushioning material in which the filaments are bonded to each other by a contact agent, which is obtained by compressing the filaments to a predetermined bulk density and applying an adhesive if necessary.

The cushion member according to the present invention as described above is manufactured as follows. For example, after compressing an aggregate of short polyester filament fibers exerting the above-mentioned steric force to a predetermined thickness, a liquid adhesive is applied by spraying, deliving, or other methods, and then it is dried. Afterwards, it is compressed to a predetermined bulk density by heating or in the presence of water vapor, and further, desired holes are drilled at predetermined locations from the bottom surface so as to almost reach the surface. A lower filament cushioning material layer as shown in FIG. In addition,
In the above method, the three-dimensionally curled filament aggregate may be subjected to needling or rubbing to increase the bulk density to some extent, and then an adhesive may be applied thereto and then molded to a predetermined bulk density by steam or hot pressing. This lower filament cushioning material layer 1 covers the holes 2.

In this case, the cross-sectional shape of the hole 2 may be circular, triangular, square, or
It may be a rectangle, a polygon such as a hexagon, or a star shape.

In addition, as shown in FIG. 4, a filament having a three-dimensional curl is placed in a mold 4 (or conveying device) consisting of a mold 4 (or a conveying device) formed by protruding a rond or pipe or bottle 3 having a predetermined cross-sectional area and shape at a predetermined location. ! - Supply short fibers 5, perform needling or rubbing if necessary, apply liquid adhesive, dry, and then compress to a predetermined bulk of 113 J in the presence of water vapor in a press machine. 5
Lower filament 1 with hole 2 as shown in figure (Δ)
A cushioning material layer 1 is obtained. In this case, the steam press may perform compression while the filament assembly is housed in the mold 4, or may be compressed after taking it out from the mold 4. In the cushioning material layer 1 formed in this way, rods or vibrators 3 corresponding to the holes 2 are inserted from the beginning, unlike the case in which the holes 2 are drilled later as in the case of Fig. 3. Therefore, there is no fear that the filaments constituting the cushioning material will be partially cut off when the holes are drilled, and the filaments constituting the cushioning material will become denser at the peripheral edge 6 of the hole 2, as shown in FIG. 5 <8). Therefore, compared to other parts, the peripheral part is 1
Since it has a kind of spring action, it gives a favorable result against elastic webbing.

Further, the upper filament cushion material layer may be made of, for example, a special
As stated in Ro Sho 51-138,669,
After canceling the polyester filament on the right side of the cotton-made three-dimensional curl, it is formed into a predetermined shape, and the three-dimensional curl filament assembly thus formed is shaped from at least one of the required directions in order to produce load strength. A needle having a barb at the tip is used to prick the body at the desired location a predetermined number of times at a predetermined needle density, and then a liquid adhesive is applied to bond each contact point between the curled filaments that make up the molded body with the adhesive. If necessary, it is compressed in the presence of water vapor to a predetermined bulk density. This is 1C%, for example, JP-A-57-37.4
As shown in No. 81, an aggregate of short filament fibers with three-dimensional curls is supplied to a conveying device, and while the conveying device is moved, a rotary body made of a large number of needle-like objects is rotated. , the needle-like object is brought into contact with the Neiramen [・short 1) AM aggregate and a predetermined portion is scraped off to preform it into a predetermined shape, and this is then formed into an endless belt and//'
Alternatively, the roller or lc is compressed by other means to form a filament aggregate 71 having a predetermined high density, and this molded product is needled with a sword equipped with barbs to a predetermined density. (rubbing may be applied before compression molding in some cases), the adhesive liquid is sprayed from above onto the filament molded body on the endless belt running in the horizontal direction, or the filament It is manufactured by immersing a molded pair in an adhesive liquid, then pulling it out of the liquid and drying it by heating. This cushioning material usually has a needle density of 1 to 100 needles/10 Q cm2, preferably 4 to 50 needles/100 cm2, and if necessary, can be pressurized in the presence of water vapor to give a needle density of 5 to 40%, preferably 10 to 30 Qcm2. %, and if necessary, it is further applied with adhesive and heat-dried.
This compression prevents "sagging" from occurring. This cushioning material can also be treated with a flame retardant to make it flame retardant.

In the above, the filament molded body is subjected to needling or rubbing, and the curled shape of the filament on the cushion side partially has directionality and is formed by expanding and contracting. We have explained the case where the partially tightly intertwined parts of the r-laments are formed in the direction that produces the load strength, and the intertwined parts are distributed according to the required load strength, but needling Rubbing or rubbing is not necessarily necessary, and may be sufficient depending on the purpose.

In this case, the filament aggregate is first shaped into a shape that is close to the final shape and relatively easy to form, as shown in FIG. 6 (Δ), and then the final shape is formed during steam pressing as shown in FIG. The shape may be made into a layer of filament 1 and a layer of cushioning material 7.

The thus obtained two and lower filament cushioning material layers 1.7 can be used as they are as cushioning members for vehicles; A moisture-curing adhesive is applied, and the adhesive is applied to the lower filament layer 1 to the cushioning material layer 1 at the contact area with the soil layer layer 7r and the cushioning layer 7, and then the presence of water vapor is applied. By compressing it downward, it is possible to bond the two together, further adjust the density of each layer, and layer the filaments on the surface. 1 Typical 4 adhesives used in the above cushion materials include synthetic rubbers such as styrene-butadiene rubber, acrylic [conitrile-butadiene rubber, chloroprene rubber, urethane rubber, etc.], natural rubber, vinyl adhesives, and vinyl acetate adhesives. , acetic acid-based adhesives, acrylic adhesives, etc., and are used in the form of latex or solution.

In this case, the aforementioned adhesives can be used alone or in combination, but even better results are obtained if the filaments are first bonded to each other with a synthetic rubber adhesive and then treated with a natural rubber adhesive. is obtained. ′? l- That is, first, the contact points of the filaments are bonded with a synthetic rubber adhesive having good adhesive properties to the synthetic fibers,
Subsequent treatment with a natural rubber adhesive improves the hardness of the bond with the synthetic rubber adhesive, the flexibility of the cushion as a whole, and the hysteresis loss and compression set of the cushion material. On the other hand, by applying the synthetic rubber adhesive in advance, the relatively low adhesion of the natural rubber adhesive to the synthetic #A fibers is improved and increased. It is preferable that the amounts of the synthetic rubber latex and the natural rubber latex adhered to each other are approximately the same, and the total amount of the applied synthetic rubber latex is approximately the same as the amount of conventional synthetic rubber latex. In addition, urethane rubber can also be used instead of natural rubber, but the combination can be considered as appropriate depending on the purpose.

The filament molded body formed as described above can be bonded by spraying the liquid adhesive from above for both the upper and lower layers, by spraying the inside of the molded body Fc with a sword-shaped sprayer, or by spraying the liquid adhesive into the inside of the molded body Fc for both the upper and lower layers. The body FC is applied by a method such as dipping into an adhesive solution, and then
10-60 at a temperature of 0°C, preferably 100-160°C
Drying or vulcanization is carried out by heating for 15 to 40 minutes, preferably 15 to 40 minutes. Note that the amount of adhesive adhered is usually 10 to 100 (+ /100 (+ - filament,
Preferably 30 to 80 (+/100 g-filament, and lower layer) In the case of a lament cushion material layer,
The final amount is 30-200(]/100(+-filaments), preferably 50-150u/100(]-filaments.

The cushion member thus formed is used, for example, as a breathable seat for a vehicle such as an automobile as shown in FIGS. 7 and 8. That is, on the surfaces of both the upper and lower filament cushion material layers 1.7, a thin breathable wadding 10 made of felt, nonwoven fabric, etc. is laminated as necessary.

In addition, the sides 11 of the cushioning layer 1.7 and the bottom 13 of the dish 12 are covered with a non-porous surface 14. Examples of the non-breathable skin body 14 include jeans, sails, etc.
'i, leather, person] - Leather, etc. Further, the surface of the cushion material layer 7 is covered with a breathable skin 15, and the peripheral portion thereof is directly connected to the non-breathable skin 14 or a part 16.
Sewn through or joined by other methods. This breathable skin body 15 is made of silk cloth, for example, lace cloth.
There are carden fabrics, raschel knits, raschel knits incorporating di-V guards, and woven fabrics (preferably coarse woven fabrics).

In FIG. 8, the dish-shaped body 12 is made of synthetic resin such as rubber, polyethylene, polypropylene, poly(A) resin such as tyrene-vinyl acetate copolymer, polyvinyl chloride, and other metals. For example, a plurality of protrusions 17 are provided at regular intervals. The cross-sectional shape of the protrusion 17 is circular, W1 circular, polygonal, cable, etc., and the number, spacing, and shape of the protrusion 17 are determined so that the dispersion of the inflowing air is as uniform as possible, as described in 4 below. It is determined by taking into consideration the support ability against the load caused by. Further, these protrusions 17 can be attached separately to the dish-shaped body, but they can be formed integrally by using methods such as blow molding, vacuum forming, and cast molding. can. A pair of plate-shaped lids 18 are placed on the upper surfaces of the dish-shaped body 12 and the protrusion 17, and are fixed to the dish-shaped body 12 at the peripheral edge or at the contact surface with the protrusion 17. A large number of ventilation holes are provided at predetermined intervals between the protrusion 17 and the protrusion 17.
τ is determined in consideration of homogeneity and dispersion. First, the air distribution chamber 20 having such a structure can be integrally molded.

At least one side surface of the air dispersion chamber 20 formed in this manner has an air introduction chamber 22 along which a plurality of ventilation holes 21 (which communicate with the air dispersion chamber 20) are bored.
is provided.

The seat body 23 as described above has a figure 8 spring 25 or other spring adjusted to the frame 24 of the seat.
It is used by placing it on a belt, etc.

At least one air introduction pipe 22 is connected to the air intake pipe 22, and the air introduction pipe 22 is connected to a fan (for example, A fan 26 is attached and connected to an air supply source. Air supply sources include air conditioners,
car cooler.

There is room temperature air inside and outside the car, and there is cold air in heated ICs.

Therefore, when connecting the air introduction pipe 22, a switching valve such as a butterfly valve (not shown) can be provided between A and A, if necessary.

Moreover, instead of this dish-shaped air distribution, it is sufficient if the air blown into the cover can pass through the epithelial layer through the cushioning material.

Next, the present invention will be explained in more detail with reference to Examples.

Example 1 An aggregate of polynisal filaments having a three-dimensional curl of 350 deniers as a monofilament was coated with the adhesive Sumikaflex 820) and then compressed in the presence of water vapor to a bulk density of 0.13 (77 cm) (adhesive). agent 180
A polyester rock material of Q/100Q-') filament) was obtained. Holes with a diameter of about 15 mm were formed in this polyester locking material in advance by protruding a rond from a mold so that the ratio of the total area of the holes to the total area of the locking material was 3%. This is used as the lower filament cushion material layer.

On the other hand, after applying needling to an aggregate of poly]-sterfilamen [~ having a three-dimensional curl of 350 deniers with a monofilament screw at a ratio of 9 filaments/100 cm2, and then applying an adhesive (Sumikaflex 900H),
Bulk density 0.048(]/c when compressed in the presence of water vapor
m3 (amount of adhesive/1.00/100 g of filament) of polyester was obtained as the upper filament/cushion material layer.

When both cushioning material layers were overlapped and subjected to CtC, repeated compression tests were conducted, and the results shown in Table 1 were exceeded. Further, the lightness of the sharpening is shown in Fig. 9 (curve Δ), and the hysteresis diagram before and after the test is shown in Fig. 110 (curve C).

Example 2 In the same method as in Example 1, the bulk density of the lower filament cushioning material layer was set to 0. 19g 7cm3, the bulk density of the upper filament cushioning material layer is 0°044 (,
A cushion member was manufactured in the same manner except that J was 7 cm3, and the same test was conducted. there were.

As described above, the present invention involves compression molding polyester fibers having three-dimensional curls into a predetermined shape, applying an adhesive to the resulting filament molded body, and bonding the contact points between the filaments. Polyester filament short fibers having three-dimensional curls are compression-molded into a predetermined shape on a lower filament cushioning material layer having a relatively high bulk density, and an adhesive is applied to the filament molded body. An upper filament cushioning material layer is formed by connecting the contact points of the filaments with each other and has a lower bulk density than the lower filament cushioning material layer, and the upper filament cushioning material layer is applied to the lower filament cushioning material layer from the lower surface thereof. Since the cushion member is characterized by forming at least one hole that reaches the material layer, it has the advantage that it has good cushioning properties but does not suffer from sagging and is highly durable. There is.

[Brief explanation of the drawing]

Fig. 1 is a partial perspective view of a double-twisted filament, Fig. 2 is a front view of a three-dimensional three-dimensional curl filament, and Fig. 3 is a lower filament cushion constituting the cushion member according to the present invention. 4 is a cross-sectional view showing the manufacturing state of the lower filament cushion material layer, and FIG. 5 (△) is a cross-sectional view showing another example of the lower filament cushion material layer. ) is a partially enlarged cross-sectional view of FIG. 5, FIGS. 6(A) and (B) are cross-sectional views showing the manufacturing process of the upper ficimen 1-cushion material layer, and FIG. 7 is a partially enlarged cross-sectional view of FIG. FIG. 8 is a perspective view of the outer seat, FIG. 8 is an enlarged cross-sectional view taken along the line 7 in FIG. 7, FIG. 9 is a graph of a repeated compression test, and FIG. 10 is a graph showing hysteresis. 1... F layer filament cushion material layer, 2... Hole, 7... Upper filament cushion material layer. Patent Applicant: Takagi Chemical Research Institute Co., Ltd. 71-sll Figure 7 (%) Procedural procedure made by IF- (Method) August 8, 1980 Commissioner of the Patent Office Kazuo Wakasugi 1. Indication of A9 1981 Patent Application No. 118,797 2 Name of the invention Cushion member 3 Person making the amendment Relationship with A' 1st name
Takagi Chemical Laboratory Co., Ltd. Representative Sadaaki Takagi 4. Voluntary amendment 6. Subject of amendment (1) Engraving of clear rllfl document 2) Engraving of drawings ・ 7. Contents of amendment

Claims (4)

[Claims] (1) Polynisdel filament that creates three-dimensional curls
A filament molded body obtained by compression molding short fibers into a predetermined shape is coated with an adhesive to bond the mutual contact points of the filaments. A polyester filament having curls [-A filament molded body obtained by compression molding short fibers into a predetermined shape is coated with an adhesive to bond the mutual contact points of the filaments, and is made from the lower filament cushioning material layer. an upper filament cushioning material layer having a lower bulk density), and at least one hole is formed in the lower filament cushioning material layer from its lower surface almost reaching the upper filament cushioning layer 471. cushion member. (2) The upper filament cushion material layer has a bulk density of 0.
The cushion member according to claim 1, wherein the upper filament cushion material layer has a bulk density of 0.1 to 0.5 g/cm3. (3) The diameter of the hole in the lower filament cushioning material layer is 1
The cushion member according to claim 1 or 2, wherein the ratio of the total area of the holes to the total area of the cushioning material layer is 0.1 to 30%. (4) The diameter of the holes in the lower filament i to cushion IJ layers is 3 to 3 Qmm, and the ratio of the total area of the holes to the total area of the cushioning material layer is 1 to 10%. The cushion member according to item 1 or 2.